Fiberglass reinforced plastic products having increased weatherability, system and method

ABSTRACT

Climbing products containing rails decorated using veil products colored, patterned, painted or in combination with marking methods such as company names and logos and resin formulation designed to withstand exposure to UV radiation with minimal change in appearance which create specific appearances for applications, enhance weathering performance, and facilitate processing efficiency. A combination of a filler free resin and coated veil systems to create a synergistic weather resistance surface with self contained color, pattern, picture, logo or combination of said same for climbing products. A system for producing components. Various methods, system, a ladder rail.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/881,591 filed Jul. 27, 2007, which is a continuation-in-partof U.S. patent application Ser. No. 11/699,254 filed Jan. 29, 2007,which claims priority from U.S. provisional application Ser. No.60/775,304 filed Feb. 21, 2006.

FIELD OF THE INVENTION

The present invention relates to the pultrusion of rail. Morespecifically, the present invention relates to the pultrusion of railusing resin without filler to increase the weatherability of the rail.

BACKGROUND OF THE INVENTION

Fiberglass reinforced plastic ladder rails are traditionally produced bythe pultrusion process. In this process, reinforcements are gatheredsystematically, impregnated with a cureable resin, formed into a shapeand cured continuously by the addition of heat in a metallic die. Theprocess has been in existence for over fifty years with little change inthe basics design of the process. During the past ten years, the federalgovernment has through the Environmental Protection Agency and throughAir Quality Standards caused the operators of the pultrusion process toreassess the methods they use to handle VOC containing resins in thepultrusion process. This has evolved several different methodologies forimpregnating reinforcement that minimize the contact of the impregnatingresin with the atmosphere and also reducing the exposure of workers tothe volatile chemicals.

BRIEF SUMMARY OF THE INVENTION

The present invention pertains to climbing products containing railsdecorated using veil products colored, patterned, painted or incombination with marking methods such as company names and logos andresin formulation designed to withstand exposure to UV radiation withminimal change in appearance which create specific appearances forapplications, enhance weathering performance, and facilitate processingefficiency.

The present invention pertains to a combination of a filler free resinand coated veil systems to create a synergistic weather resistancesurface with self contained color, pattern, picture, logo or combinationof said same for climbing products. Resins can be generically ofpolyester, acrylic, epoxy, urethane, acrylate, and or combinations ofsaid resins. Veils may dyed, printed, pigmented, transfer coated orcombinations of said methods familiar to one skilled in the state of theart. Veil compositions may be glass, polyester, paper, jute or otherdispersed fiber systems capable of maintaining mechanical anddimensional performance throughout the ladder section productionprocess.

The present invention pertains to a method for continuously placingspecific amounts of internal structural resin into a product bybalancing the volume flow of input internal structural resin in anenclosed impregnation system to the size of the product and the linespeed of the manufacture process.

The present invention pertains to the use of a central reinforcement tocarry structural resin and maintain distribution of structural resinthrough the impregnation process to the curing die.

The present invention pertains to the use of specific reinforcementsystems and impregnation processes to self limit the amount ofstructural resin introduced into a laminate during the impregnationprocess by using the absorptivity and compression characteristic of theinternal reinforcement to carry said resin through the process andtransfer said resin to adjacent unwet structural layers prior to thecuring process of the resin in the manufacturing process.

The present invention pertains to a method for changing part colorwithout stopping production which minimizes total raw material lost andproduct lost to mixed appearance.

The present invention pertains to a method of folding veils such thatthe crossovers between veils are located and controlled at a prescribedpositions on the part.

The present invention pertains to a method for continuously producing onseparate streams of a single machine colored parts of differing color.

The present invention pertains to a method for continuously producingparts with differing colors in controlled positions around the perimeterof the said parts.

The present invention pertains to a method for continuously producing onseparate streams of a single machine colored parts of differing colorwhile continuously producing parts with differing colors in controlledpositions around the perimeter of the said parts.

The present invention pertains to a system for producing components. Thesystem comprises means for producing rail having a delta E less than 20with a 60 degree gloss, as measured by a 100 gloss meter, of greaterthan 70 after 1000 hours of accelerated weathering in a QUV chamberusing bulb A with an ASTM cycle. The system comprises means for cuttingthe rail.

The present invention pertains to a ladder rail. The rail comprises aweb. The rail comprises a first flange extending from the web. The railcomprises a second flange extending from the web. The web and first andsecond flanges made of fiberglass and resin and together forming therail having a delta E less than 20 with a 60 degree gloss, as measuredby a 100 gloss meter, of greater than 70 after 1000 hours of acceleratedweathering in a QUV chamber using bulb A with an ASTM G154 cycle 4.

The present invention pertains to a method for producing components. Themethod comprises the steps of producing rail having a delta E less than20 with a 60 degree gloss, as measured by a 100 gloss meter, of greaterthan 70 after 1000 hours of accelerated weathering in a QUV chamberusing bulb A with an ASTM G154 cycle 4. There is the step of cutting therail.

The present invention pertains to a system for producing a ladder rail.The system comprises a pultrusion system. The pultrusion systemcomprises a prewet which wets a middle mat with a resin and filler. Thepultrusion system comprises an impregnator which compresses a first veilouter layer, a second veil outer layer, a first mat layer, a second matlayer, a first roving layer and a second roving layer with the middlemat, and which wets only the first veil outer layer, the second veilouter layer, the first mat layer and the second mat layer with resinwithout filler.

The present invention pertains to a ladder rail. The rail comprises afirst veil layer. The rail comprises a first mat layer having a firstcolor in contact with the first veil layer. The rail comprises a firstroving layer in contact with the first mat layer. The rail comprises amiddle mat layer in contact with the first roving layer. The railcomprises a second roving layer in contact with the middle mat andtogether the middle mat and first roving layer having a second color.The rail comprises a second mat layer having the first color in contactwith the second roving layer. The rail comprises a second veil layer incontact with the second mat layer.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawings, the preferred embodiment of the inventionand preferred methods of practicing the invention are illustrated inwhich:

FIG. 1 is a schematic diagram of the pultrusion process.

FIG. 2 shows a section of a pultruded profile.

FIG. 3 is a schematic of the basic pultrusion process.

FIG. 4 shows the relative thickness of the layers of pultruded section.

FIG. 5 shows a seven layer laminate.

FIG. 6 shows through a three layer laminate.

FIG. 7 shows a side view of the pultrusion piece.

FIG. 8 a shows a preform injection design.

FIG. 8 b shows a graph of the pressure in the weir versus the pressurealong taper in impregnation section.

FIG. 9 shows a schematic of the controller impregnation.

FIG. 10 shows section C of FIG. 9.

FIG. 11 shows section B of FIG. 9.

FIG. 12 shows section A of FIG. 9.

FIG. 13 shows a prewet station.

FIG. 14 shows a bottom view of the internal top half of the prewetstation.

FIG. 15 shows a top view of the internal bottom half of the prewetstation.

FIG. 16 shows a side sectional view of the pre-wet station.

FIG. 17 shows a front view of the slot where Q is greater than R.

FIG. 18 shows a front view of the slot where Q is much greater than R.

FIG. 19 shows a front view of the slot where Q equals R.

FIG. 20 is a front view of a prewet station with a variable slotversion.

FIG. 21 is a side view of a prewet station with a variable slot version.

FIG. 22 is a perspective front view of a continuous former.

FIG. 23 is a perspective back view of the continuous former.

FIG. 24 is a graph of the prewet resin versus the pump capacity.

FIG. 25 shows a climbing product of the present invention.

FIGS. 26 and 27 are photographs of portions of ladder rails withgraphics.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein like reference numerals refer tosimilar or identical parts throughout the several views, and morespecifically to FIG. 25 thereof, there is shown climbing products 55containing rails 16 decorated using veil products colored, patterned,painted or in combination with marking methods such as company names andlogos or graphics and resin 14 formulation designed to withstandexposure to UV radiation with minimal change in appearance which createspecific appearances for applications, enhance weathering performance,and facilitate processing efficiency. A logo and/or a picture is part ofthe veil itself. The graphics can also include patterns, artworkreplications, photographic images, and blends of transitional colors inthe veil.

The present invention pertains to a combination of a filler free resin14 and coated veil systems 10 having graphics to create a synergisticweather resistance surface with self contained color, pattern, picture,logo or combination of said same for climbing products. Resins 14 can begenerically of polyester, acrylic, epoxy, urethane, acrylate, and orcombinations of said resins 14. Veils may dyed, printed, pigmented,transfer coated or combinations of said methods familiar to one skilledin the state of the art. Veil compositions may be glass, polyester,paper, jute or other dispersed fiber systems capable of maintainingmechanical and dimensional performance throughout the ladder section 52production process. Preferably, when graphics are used with the veil, acombination of a resin having filler levels below 20 pph, and morepreferably between 5 pph and 20 pph, is used with a coated veil systemto create a synergistic weather resistance ladder rail surface withgraphics.

The present invention pertains to a method for continuously placingspecific amounts of internal structural resin 14 into a product havingveil with graphics by balancing the volume flow of input internalstructural resin 14 in an enclosed impregnation system 10 to the size ofthe product and the line speed of the manufacture process.

Preferably, there is an enclosure design, such as an injection die thatcontinuously distributes the resin 14 in planned uniform or non-uniformvolume across the width of the part 40 to match the volume ofreinforcement in the specific locations throughout the cross section ofthe part 40.

The present invention pertains to the use of a central reinforcement tocarry structural resin 14 and maintain distribution of structural resin14 through the impregnation process to the curing die.

The present invention pertains to the use of specific reinforcementsystems 10 and impregnation processes to self limit the amount ofstructural resin 14 introduced into a laminate during the impregnationprocess by using the absorptivity and compression characteristic of theinternal reinforcement to carry said resin 14 through the process andtransfer said resin 14 to adjacent non-impregnated structural layersprior to the curing process of the resin 14 in the manufacturingprocess.

Preferably, the method insures placement of said resin 14 such that thesurface resin 14 and any structural resins 14 do not intermix yetco-cure to a laminate whose structural and functional properties aresufficient for use in climbing products. (ladders)

The present invention pertains to a method for changing part 40 colorwithout stopping production which minimizes total raw material lost andproduct lost to mixed appearance.

Preferably, the color is changed by introducing veils of differing coloraround the perimeter of the part 40. Preferably, said veils areintroduced without attaching said veils to the veils of the previouscolor(s) in the process.

The present invention pertains to a method of folding veils such thatthe crossovers between veils are located and controlled at prescribedpositions on the part 40.

The present invention pertains to a method for continuously producing onseparate streams of a single machine colored parts 40 of differingcolor.

The present invention pertains to a method for continuously producingparts 40 with differing colors in controlled positions around theperimeter of the said parts 40.

The present invention pertains to a method for continuously producing onseparate streams of a single machine colored parts 40 of differing colorwhile continuously producing parts 40 with differing colors incontrolled positions around the perimeter of the said parts 40.

The present invention pertains to a system 10 for producing components.The system 10 comprises means for producing rail 16 having graphicshaving a delta E less than 20 with a 60 degree gloss, as measured by ahunter gloss meter, of greater than 70 after 1000 hours of acceleratedweathering in a QUV chamber using bulb A with an ASTM cycle. The system10 comprises means for cutting the rail 16.

The present invention pertains to a ladder rail 16. The rail 16comprises a web 18 having a graphic. The rail 16 comprises a firstflange 20 extending from the web 18. The rail 16 comprises a secondflange 22 extending from the web 18. The web 18 and first and secondflanges 20, 22 made of fiberglass and resin 14 and together forming therail 16 having a delta E less than 20 with a 60 degree gloss, asmeasured by a hunter gloss meter, of greater than 70 after 1000 hours ofaccelerated weathering in a QUV chamber using bulb A with an ASTM G154cycle 4.

The present invention pertains to a method for producing components. Themethod comprises the steps of producing rail 16 having graphics having adelta E less than 20 with a 60 degree gloss, as measured by a huntergloss meter, of greater than 70 after 1000 hours of acceleratedweathering in a QUV chamber using bulb A with an ASTM G154 cycle 4.There is the step of cutting the rail 16.

The present invention pertains to a system 10 for producing a ladderrail 16. The system 10 comprises a pultrusion system 10. The pultrusionsystem 10 comprises a prewet 24 which wets a middle mat with a resin 14and filler. The pultrusion system 10 comprises an impregnator 26 whichcompresses a first veil outer layer 12, a second veil outer layer 28, afirst mat layer 30, a second mat layer 32, a first roving layer 34 and asecond roving layer 36 with the middle mat, and which wets only thefirst veil outer layer 12, the second veil outer layer 28, the first matlayer 30 and the second mat layer 32 with resin 14 without filler.

The resin 14 in the prewet 24 can be the same or different, i.e., color,from the resin 14 in the impregnator 26.

Preferably, the first and second veil outer layers contain all thecolorant needed to color the ladder rail 16. Preferably, the first andsecond outer veil layers combined with the resin 14 without filler forma corrosion and weathering barrier such that said ladder rail 16maintains a delta E of less than 20 and 60 degree gloss of 60 afterexposure to 1000 hr of ASTM G154 Cycle 4 irradiation in a QUVaccelerated weathering machine.

The first and second outer veil layers can contain more than one color.The first and second outer veil layers can contain pictures and printedletters or words and/or graphics.

The present invention pertains to a ladder rail 16. The rail 16comprises a first veil layer having graphics. The rail 16 comprises afirst mat layer 30 having a first color in contact with the first veillayer. The rail 16 comprises a first roving layer 34 in contact with thefirst mat layer 30. The rail 16 comprises a middle mat layer 38 incontact with the first roving layer 34. The rail 16 comprises a secondroving layer 36 in contact with the middle mat and together the middlemat and first roving layer 34 having a second color. The rail 16comprises a second mat layer 32 having the first color in contact withthe second roving layer 36. The rail 16 comprises a second veil layer incontact with the second mat layer 32.

Preferably, the first mat layer 30, and the second mat layer 32 havingresin 14 without filler; and the first and second roving layers 34, 36and the middle mat layer 38 having resin 14 with filler.

In the operation of the invention, colored veil offers a low costapproach for meeting commercial objectives of improved fiberglassproduct performance, particularly that of weathering characteristics.

Colored veil advantages relative to ladder and climbing products thatuse reinforced fiberglass plastic (FRP) components are centered onimproved weather resistance and the reduction of manufacturingchange-over costs from color to color with traditional pigmented resin14 processes. An un-colored, unfilled clear resin system 10 is usedtogether with pre-colored veil to produce the composite component insubstitution for color-pigmented resin 14 with un-colored veil.

Manufacturing equipment and tooling configurations that provide separateresin 14 delivery to the periphery of the composite's cross section andto the cross section's interior is utilized to:

-   -   1. Improve weathering characteristics by using higher        performance resin 14 formulation on the component's exterior.    -   2. Lowered cost by using standard resin 14 formulations in the        interior cross sectional area and reductions in manufacturing        change-over time and associated material scrap.    -   3. Flexible manufacturing for prototype samples, marketing        promotions, and special orders.    -   4. Efficiencies of demand balance of production lines where a        production machine can pultrude composite streams in different,        separate colors simultaneously, rather than limited to a single        color from a common pigmented resin 14 bath supply.    -   5. Pre-colored and pre-printed veil allows introduction of        graphics, patterns, color combinations, logos, and brand names        into the product's appearance.

Process Description

The methods are generically some form of closed or partially closedimpregnation bath or die run at either ambient or elevated pressure.These “injection” dies have been disclosed in various patent literature(see U.S. Pat. No. 6,048,427 by Gauchel et. al.; U.S. Pat. No. 5,783,013by Beckman and Gauchel; U.S. Pat. No. 5,747,075 by Gauchel et. al.; U.S.Pat. No. 5,322,582 by Davies et. Al.; and U.S. Pat. No. 3,684,622 byGoldsworthy; all of which are incorporated by reference herein, andwhich describe Pultrusion). Each of these patents teaches methods forplacing resin 14 or resins 14 into or uniformly through the part's 40cross section. Davies discusses using discrete roving packets toselectively place a second resin 14 locally within a part 40. Gaucheland Beckman discuss methods for selectively impregnating various parts40 of the reinforcement package by either separate die technology ofseparate weir 42 technology. Goldsworthy uses multiple impregnationports and internal injection systems to place resin 14 into thereinforcement pack. In all cases no attempt is made to insure that themultiple resins 14 are maintained in discrete layers through thethickness of part 40 along the length of the part 40.

In this invention, the teachings referenced above are improved bycreating mass flow conditions which cause multiple resins 14 to remainin specific areas within the part 40 (placement of resin 14 isaccomplished by contacting resins 14 with selected reinforcements in thestacking sequence (donor layers) of the part 40, i.e. the middle mat,supplying the resin 14 at a known rate sufficient to remove the air fromthe reinforcement when it is compressed and compressing thereinforcement to a given thickness distribution along the width of themat. For samples of constant cross section and glass content theimpregnated reinforcement would be compression uniformly across thewidth. The degree of compaction is determined mathematically bycalculating the amount of resin 14 needed to fully saturate thereinforcement at the thickness it will be compacted to in the final part40 plus the amount of resin 14 needed to transfer from thepreimpregnated mat to the adjacent layers (acceptor layers). This amountis determined from the amount of glass in the acceptor layers and thefinal thickness of the acceptor layers in the cured part 40. (All glassroving layers are optimally impregnated with standard density resin 14at a weight percent of approximately 75%. Glass Mat layers compacted totheir final thickness in the die are fully saturated at about 35% byweight.)

Transfer to the acceptor layer is only accomplished as the reinforcingpack is compressed in the forming process prior to introduction of thetopcoat in the injection die. The design of the forming station andimpregnation die is such that the reinforcement pack is compressed towithin 0-5 mils of the thickness of the part 40 in the curing die priorto addition of the second resin 14.

If more than two resins 14 are used, the thickness would be compressedsuch that layers to be impregnated by the first resin and the donorlayer of the second resin are compressed to a calculated thickness suchthat the first layer and its receptor layers are impregnated with theinitial resin 14 and the second donor layer is compressed to the properthickness to accept the proper amount of resin 14 to impregnate itselfplus its acceptor layers. The process is repeated depending on thenumber of resins 14 that are being introduced to the part 40.

Along with process improvement, a materials modification of using acombination of surfacing veil to which has been addeddies/pigments/paints to selectively or uniformly color the part's 40exterior and a resin 14 formula designed from resin 14 types known tohave the combination of weathering performance and processing capabilityin the pultrusion process and additive packages which minimizedegradation of the resin 14 on weathering and placing said resin 14 aveil on the exterior of the part 40 to create a part 40 with weatheringcharacteristics superior (as measured by change in appearance—gloss andcolor change (delta E value from spectrophotometer)—after exposure toknown quantities of light in a QUV-accelerated weathering apparatus tothe current state of the art for materials produced from the pultrusionprocess.

While modified surfacing veils have been used to develop functionalcharacteristics in pultruded parts, they have not be used with highperformance unfilled resins 14. The reason was that to use the highperformance resins 14 throughout the part thickness was not costeffective. But if the modified veil and high performance resins 14 areused with the process modifications of this invention, only a thin layerof high performance resin 14 needs to be used to create a functionallyweathering layer, see above description of resin 14 placement method.Because this invention allows varying the thickness of the layer ofreinforcement available for impregnation by the clear outside corrosionresin 14 by either selection of the thickness of the outsidereinforcement and/or control of the amount of inside resin(s) 14 placedon the donor layer(s) of the part 40, a cost effective laminate may beobtained which has better measurable response to accelerated weatheringwhile maintaining the needed structural performance for climbingproducts as measured by performance in ANSI14.5 testing protocols,incorporated by reference herein.

Other aspects of this invention relate to the synergy between the use ofcolored veil, selective resin 14 placement and process techniques. Theseinteractions create improvements in scheduling flexibility, productdiversity and manufacturing efficiencies which lead to increasedproductivity. One example of the improvement in process scheduling thatoccurs when parts 40 of varying color can be run simultaneously on onemachine. Currently all streams on a given pultruder run parts 40 withthe same color resin 14 supplied to each stream from a single holdingtank-excess resin 14 is collected and recycled to the input holding tankand reused. To run individual steams with different color resin 14multiple holding pots with separate pumps and resin 14 recycle hardwarewould be required. Not only would this be expensive but because of thelimited space on the machine difficult and cumbersome to the operator.Introducing colored veil allows the existing hardware to be used becauseonly non-colored resins 14 are required. Each stream on a multi-steammachine is capable of running its own color as determined by the colorof this input veil used in the part 40.

Likewise products with multicolors, patterns or pictures can be producedusing the appropriate incoming veil manufactured by standard veilprinting and dying techniques to colors which when put through the rail16 making process produce colors that are selected to match standardsdesired by marketing for specific ladders—example a deep blue for theelectricians ladder actually starts with a veil whose color appears tobe too red and too purple to create the desired color. Color shiftsthrough the process are determined experimentally and vary by color.

Changing colors also becomes extremely easy. Changing standard veils iscommonly done during processing. The veils are allowed to run out in arandom manner and are replaced as needed. This can be done on the flywith little or no scrap and no down time. With colored veils the onlymodification is that if a color change is occurring all veils on thepart 40 need to be changed within a small distance of each other tominimize scrap do to multicolored parts 40. Otherwise, no shutdown forcleaning or transfer of one colored resin 14 out of the system 10 andplacement of the new color into system 10 is required—no scrap or unusedresin 14—no loss of productivity while the resin 14 change occurs—nomess associated with cleaning guides 48 and resin 14 return pans etc.

With proper guidance methods, veils do not even require attachmentbetween ends of preceding and subsequent veils, thus eliminating morework for the machine operator.

If entire operations are converted to this process, other synergiesoccur in the mixing and resin 14 delivery systems which further improvethe cost effectiveness of the product. One topcoat and one structuralresin 14 formula can be used for all colors and shapes with the coloredveil process we would have only one prewet 24 formula and one topcoatformula for all colors and locations. The mix room would make prewet 24and topcoat only not multiples of each. Thus, knowing the relativerequirements of each resin 14 for each part 40, resin 14 mixing volumesmay be optimized so that minimal excess of any resin 14 is obtainedduring the mixing operation. All topcoats are equal and can be sent toany line. Likewise, all structural resin 14 batches are the same and canbe utilized by every machine. No more having too much blue and notenough yellow to meet a varying demand. Color is now dependant on longterm stable veils systems capable of being inventoried without fear ofloss by reaction.

Cleanup between color changes is virtually eliminated. Preventivemaintenance on lines and pumps replaces requirements for purging systemswith solvent and unpigmented resins 14 to clean lines in order to run alight color after a dark one.

Running colored or printed veils requires ungrading the quality ofreinforcement placement during the pultrusion process. Veil placementmust be maintained constant so that any overlaps occur in the properlocation. The upside of the placement issue is that with properplacement techniques veils no longer need to be as wide. Current veilsare extra wide to take into account lateral shrinkage and to make surethere is a bunching of veil at the tips of flanges. This means that thestandard veils are between 0.5 and 1.0 wider than need to cover theperimeter of the part 40. Colored veils shrink less during the processand the placement is more consistent because a veiless surface cannot beallowed to occur. Bunching is also not wanted on the tipps with coloredveil because it causes the tips to be a different color than the rest ofthe part 40. The consistent placement is created with an added veilfolding device(s) which allow the veil to fold only one way. Reducingveil width creates a measurable materials savings.

In regard to weathering cycle, see ASTMG154 Cycle 4, incorporated byreference herein. Relative weathering performance for yellow part

1. Previous standard overcoat Delta E = 40 1000 hrs QUV 2. StandardThrough color/RI = 35 3. Colored veil with stand resin = 35 4. Coloredveil with no filler resin = 12 (the present invention)

-   -   1000 hrs QUV=1 year south Florida for the cycle we are using    -   Delta E above 20 is cut off for acceptable performance    -   Processing with colored veil takes color change from multiple        hours to about a minute    -   Colored veil allows different colors on same machine        simultaneously    -   Colored veil allows different colors on same part. The gloss of        the rail 16 is greater than 70.

DEFINITIONS Donor Layer

A layer of reinforcement(s): the donor layer may consist of multiplereinforcements such as mat plus roving or multiple mats but is normallya single mat that is impregnated directly with resin 14 in anuncompressed or partially compressed state such that the amount of resin14 transferred to the layer is sufficient to fully impregnate itselfplus impregnate the acceptor layer(s) adjacent to it in the curedlaminate. The characteristics of a donor layer are that it is uniformlycompressible, compressibility versus pressure is known and reproducible,structure is such that it can accept and give up resin 14 easily ascompressed, and that its structure is such that it will maintain a nonuniform resin 14 distribution over the time frame of the impregnation,combination and forming processes so that a distributed resin 14 volumemay be transferred to the acceptor layers.

Acceptor Layer:

A layer of reinforcement usually roving which is put into thecombination and forming process in an unimpregnated or partiallyimpregnated state. Impregnation of the acceptor level occurs as it iscombined with a donor layer and the donor layer/acceptor layer(s)package is compressed in the forming and final impregnation stations ofthe process.

Combination Process:

A segment of the total pultrusion process that brings layers ofreinforcement together into a reinforcement package. The combinationprocess normally is placement only with little or no compaction of thelayers.

Forming Process:

A segment of the total pultrusion process that takes the fully combinedreinforcement package (including impregnated donor layers) and shapesthem from a flat or slightly curves shape to a shape similar to theshape of the curing die but slightly larger in all dimension.

Final Impregnation Process:

A segment of the total pultrusion process that compacts thereinforcement package causing the donor layers to release resin 14 tothe acceptor layers and brings the reinforcing package to the size ofthe curing die, and simultaneously adds topcoat resin 14 under pressureand removes and remaining air from the reinforcement package. Thisresults in a fully impregnated reinforcement package with donor resin 14distributed throughout the donor acceptor layers and topcoat resin 14distributed in the outside topcoat containment layers (normally thiswould be the veil and the outside mat layers of our standard seven layerlaminate, but we could use other types of reinforcements under the veilto contain the topcoat resin 14)

Pultrusion Process

Sizing the opening in the prewet 24 die

-   -   1. What is the amount of resin 14 required to fully saturate a        layer of given thickness for common pultrusion reinforcements?        -   Requires knowing the volume occupied by the reinforcement            layer in a cured pultrusion laminate

Reinforcement Type Thickness in Pultruded laminate (in)

1 oz continuous filament mat .020 .625 oz Holinee Madiglioni Mat .020.75 oz continous filament Mat .017 uniform layer of roving (250 yield).0224

-   -   and it also requires knowing the percentage of the reinforcement        layer the reinforcement actual occupies (the rest is occupied by        the resin 14)

Equilibrium Glass Volume Fraction in Pultruded Layer

1 oz continuous filament mat .23 .625 oz Holinee Madiglioni Mat .151uniform layer of roving (250 yield) .60

One then can calculate the split in thickness between reinforcement andresin 14.

Thickness Occupied by Reinforcement and Resin 14 in Pultruded Layer

Reinforcement (in) Resin (in) 1 oz continuous filament mat .0046 .0154.625 oz Holinee Madiglioni Mat .0031 .0169 uniform layer of roving (250yield) .00134 .009

-   -   2. From the above data one can now size the preimpregnation        station exit slot 50. If a 0.625 Holinee mat is used as a donor        layer for two acceptor layers of 250 roving, the Holinee mat        must contain on exit of the preimpregnation chamber enough resin        14 to fully saturate all three layers. This would be 0.0154 in        of resin 14 for the mat itself plus 0.018 in of resin 14 for the        roving layers (2×0.009). Thus, the total thickness of the mat on        exit of preimpregnation chamber should be 0.0031 for the glass        in the mat+0.0334 for the resin 14=0.0364 inches. Since Holinee        mat in the unimpregnated state is 0.079, the mat will accept and        hold this amount of resin 14 with minimal transfer of resin 14        during the combination and forming process. Only when compaction        of the mat to less than a thickness of 0.0364 inch will resin 14        transfer from the donor mat to the acceptor rovings. Formers 46        are designed with a 1.5 factor on all dimensions so that the        thickness available in the former 46 for a holinee layer is        0.020×1.5=0.0300. Thus, thirty-three percent of the total        transfer to the acceptor roving takes place prior to the final        impregnation chamber.

Composition for Best Practice for this Invention:

-   -   1. Use of 0.625 oz/sq ft Holinee mat as central donor.    -   2. Use of 2 1 oz/sq ft Continuous Filament Mats (from either OC        or CSG) as Outside structural layers    -   3. Use of 2 layers of continuous roving (250 yd/lb        yield—multiple sources) placed such that each layer contains 11        rovings per linear inch of width    -   4. Use of 2 layers of dyed polyester veil from Precision Fabrics        Group (PRG) each layer weighs 1.65-2.5 oz/square yd. depending        on color. For orange a weight of 1.75 oz/yd gave the best        compromise of initial color and retention on weathering.    -   5. Prewet 24 formulation based on AOC P 920-300 DCPD end capped        polyester resin 14 with 18-25 pphr fillers such as kaolin clay,        calcium carbonate or combinations of calcium carbonate and clay;        [The most used mixture is 14.25 pphr of Wilklay SA-1 kaolin clay        and 14.25 pphr of Hubercarb W3 calcium carbonate] 1 pphr of        internal release [Axel IntPul 24] and 0.9 part of peroxide        initiator(s) [we use three initiators—a low temperature, mid        temperature and high temperature combination (luperox 223V75,        tertiary amyl peroxyethylhexanote, and        tertiarybutylperoxybenzoate) in a 6:2:1 ratio].    -   6. A topcoat resin 14 with the same ingredients and ratios        except the fillers are removed.

Holinee mat is pulled through a prewet 24 station with an exit slot 50width of 0.036+/−0.003 inches. The prewet 24 station is supplied withsufficient resin 14 such that the reservoir within the prewet 24 stationremains full and resin 14 does not exit the input slot 50 where the matenters the prewet 24 station. This input flow is determined for eachprewet 24 station from calibration runs of Mass flow versus flowsetting, the size of the part 40 and the amount of resin 14 beingtransferred to the donor layer.

Calibration method:

-   -   1. Weigh 3 containers    -   2. Set flow gage on prewet 24 pump to setting A    -   3. Pump resin 14 into Container for 2 minutes    -   4. Reweigh container and calculate mass flow (weight/min)    -   5. Repeat step 2-4 for settings B and C    -   6. Using results, plot chart of mass flow versus setting for        particular pump/prewet 24 station combination    -   7. Using chart and weight requirements for donor layer select        setting for prewet 24 pump which is balanced to output        requirement.

Referring to FIG. 1, the pultrusion process, very similar to extrusion,is the only continuous process for the production of composite profiles.In pultrusion, reinforcing materials (glass, Kevlar or carbon fibers) inthe form of continuous rovings, mats and other types of fabrics, arepulled through a resin 14 matrix bath or other impregnation device, thencarefully guided through a pre-shaping station followed by a heated,high precision, die in which the resin 14 matrix sets at hightemperature to form the final product. Finally, the hardened profile iscontinuously pulled past a saw, activated to cut it into pre-determinedlengths.

Pultruded Composites

A pultruded composite is generally made up of reinforcing materials(glass, Kevlar, carbon fibres) held together by a rigid resin 14 matrix(polyester, vinylester, epoxy thermosetting resin 14). Often, surfaceveils are incorporated to improve weathering and corrosion resistance.

FIG. 2 shows a typical section 52 of a pultruded profile for generaluse.

While pultrusion machine design varies with part 40 geometry, the basicpultrusion process concept is described in FIG. 3.

The creels position the reinforcements for subsequent feeding into theguides 48. The reinforcement must be located properly within thecomposite and controlled by the reinforcement guides 48.

The resin 14 impregnator 26 saturates (wets out) the reinforcement witha solution containing the resin 14, fillers, pigment, and catalyst plusany other additives required. The interior of the resin 14 impregnator26 is carefully designed to optimize the “wet-out” (complete saturation)of the reinforcements.

On exiting the resin 14 impregnator 26, the reinforcements are organizedand positioned for the eventual placement within the cross section formby the preformer. The preformer is an array of tooling which squeezesaway excess resin 14 as the product is moving forward and gently shapesthe materials prior to entering the die. In the die the thermosettingreaction is heat activated (energy is primarily supplied electrically)and the composite is cured (hardened).

On exiting the die, the cured profile is pulled to the saw for cuttingto length. It is necessary to cool the hot part 40 before it is grippedby the pull block (made of durable urethane foam) to prevent crackingand/or deformation by the pull blocks. Two distinct pulling systems areused: a caterpillar counter-rotating type and a hand-over-handreciprocating type.

The entire part 40 of the invention that is being described takes placefrom the exit of the guide plate to the entrance of the curing die. Therest of the pultrusion process is essentially unchanged.

FIG. 4 shows the relative thickness of the various layers of thepultrusion. The outer layer is formed of the colored veil which isthinner relative to the inner layers. As an example, the thickness ofthe colored veil layer is about 0.005 inches.

FIG. 5 shows a cross-section of a seven layer laminate. The impregnatedouter mat layers will take on the combined color (appearance of theglass composition and of the filler resin 14). The central roving matroving layer takes on the color of the filler resin 14, which can be offwhite. The veils are the color they are dyed.

FIG. 6 is a cross-section of a three layer laminate. The colored veilouter layers can have the color they are dyed, while the mat layer incontact with the outer veil layer can be slightly green. The innerrovings and mat layers are saturated with filler resin 14 and can bewhite. The colored veil and mat layers are typically 0.024-0.030 inchesthick while the inner rovings and mat layers are typically 0.065-0.070inches thick. The overall thickness of the laminate is typically between0.113-0.130 inches thick. The formed laminate of FIG. 6 is shown in FIG.7.

Referring to FIGS. 8 a and 8 b, they are a schematic of a generalizedinjection die with resin 14 overflow return lines. The objective of theimpregnation die is to finish the impregnation of the reinforcement packstarted by the prewet 24. In order to do this the impregnation die isdesigned with a slight taper. The taper compacts the reinforcement packsuch that the prewet 24 resin 14 in the donor mat is transferred to theacceptor layers of the reinforcement pack while leaving the outer layers(mat and colored veil unimpregnated and available to accept resin 14from the weir 42 and act as a continuous path for air removal from thereinforcement pack within the injection die to the atmosphere. Bycarefully designing the thickness tapers of the injection die such thatthe minimum thickness is equivalent to the thickness the reinforcementpack would be compacted to within the curing die and this thicknessoccurs at the downstream end of the weir 42 (resin 14 input device) apressure gradient is set up within the impregnated area of thereinforcing pack which forces the flow of fluid (air and/or resin 14)toward the entrance of die. As long as an uninterrupted path ismaintained between the leading edge of the resin 14 in the wedge 44 andthe entrance of the impregnating die air will flow out of the entranceof the die and no voids will enter the curing die. If however too muchprewet 24 is applied to the donor layer and or the design of the taperin the injection die is incorrect and resin 14 blocks the outer layersof the reinforcing pack, air with be trapped in the pack and transferredto the curing die where it will form either a blister or crack in thecured laminate as it exits the curing die. The prewet 24 is designed bycontrolling pressure and dimensions to transfer limited amounts of resin14 so that as the partially impregnated reinforcing pack is compacted inthe injection die taper there is insufficient volume of resin 14 toimpregnate all the layers between the donor layer and the die surface.The injection die is designed so the taper is continuous and gradual sothat transfer from donor layer to acceptor layers would be uniform. Bothdesigns are balanced so that the result is a system which allows forcontinuous air removal as the final part 40 of the reinforcing pack isimpregnated with the topcoat resin 14 in the impregnation die.

FIG. 8A shows a cross-sectional side view of the preform injection diedesign. Partially impregnated reinforcement enters the right side of thepreform. Air that is carried into the preform with the reinforcementalso escapes back out the opening. Excess resin 14 that is squeezed outof the reinforcement is collected and returned for reuse throughopenings in the preform near the entrance. The slot 50 through which thereinforcement passes forms a tapered wedge 44 in the die startingessentially at about its center. The fully impregnated reinforcementpasses through the weir 42 which receives resin 14 under pressure thatis inputted from a pressure pot. After the impregnated reinforcementpasses through the weir 42 and receives the resin 14 in the weir 42, itpasses out of the preform and moves to the curing die. FIG. 8B shows thepressure in the die of the preform as a function of location in the die.The pressure is highest between the weir 42 and the exit, where it isessentially constant, or slightly increasing. The pressure before theweir 42 is essentially of a constant slope increasing along the taperedwedge 44. Before the tapered wedge 44 the pressure is essentiallyconstant in the die and about that of atmospheric pressure.

The weir 42 has the following constraints.

-   -   1. it must be of a size to transfer sufficient resin 14 to the        part 40 to fill the unwet layers (width fixed by 3. below, this        normally set depth—(the Q in the slot 50 should be higher than        the required Q to wet the part 40).    -   2. it must be of sufficient length such that the entire        perimeter of the part 40 is wet.    -   3. A guideline that contact time of 1 second would be good        however it is preferably 0.5 secs. contact time=weir 42        width/line speed for example a one inch wide weir 42 run at 100        inches per min would have a contact time of 1/100 minutes or 0.6        seconds    -   4. It can't be too wide; otherwise, the veils catch and roll        inside the weir 42 and there can be no dead spots where material        could accumulate and cure. (This defines shape.)

A clear distinction between the composition of resin 14 in the rovingslayers and the composition of resin 14 in the outer mat layers ismaintained by the physics of the process. It insures the resin 14without filler in the outer mat layers is not mixed with resin 14 withfiller from the donor layer so the increased weatherability of the rail16 produced is maintained.

Because the resin 14 and filler from the donor layer in the rovingslayer is there first and the pressure required to move it is higher thanthe back pressure along the unimpregnated outer mat—resin 14 fromimpregnation weir 42 follows a path—the one of least resistance-onlyinto the outer mat layers.

The compaction of the reinforcing pack has already pushed the resin 14in the central donor mat into the acceptor roving layers. This processoccurs prior to the external veil and roving seeing the high pressureresin 14 at the weir 42. With a taper of 0.003 in/in and thickness atthe weir 42 of <0.001 in larger than the final dimensions in the curingdie, all but the final 2 mils of compaction of the donor layer occursbefore 5 inches behind the weir 42. This means that the resin 14 fromthe donor layer should have reached within 0.002 inches of the outsideedge of the roving layer.

Referring to FIGS. 2, 4, 5, and 6 because there is control where theprewet 24 resin 14 and the topcoat resin 14 goes within the part 40 thecross section of a part 40 made with this type of process is easilydistinguished from a part 40 made by conventional wetting methods. Thisis especially true with systems where a pigmented veil is used as thesource of color within the part 40. If one polishes the cross section ofa ladder rail 16 using normal polishing methods (reference) the layersof reinforcement within the part 40 are visible by optical microscopy,The layers may be separated by machining away layers and leaving aspecific layer exposed on the surface of the part 40. Each layer may beisolated and visually examined and/or examined using other instrumentedor non-instrumented methods (burn off to determine if the outer layershave filler). One skilled in the art can look at the cross section andsee if some form of colored veil is contained in the process evenwithout help of the microscope. Thus, samples of ladders manufactured bycompetitors who would ignore this patent could be found out with minimumdifficulty in the laboratory and even be screened by visually looking acut edges of the rail 16 without destroying the part 40. A diamond orcarbide cut off saw is used to create a 1 thick piece of the section 52.This section 52 is put in clear epoxy resin 14; cure and polish thesurface of the cast segment—using techniques developed for polishingmetal surfaces for grain analysis. The polished surfaces can be lookedat under optical microcopy and each layer distinguished as to type.Because the topcoat resin 14 and prewet 24 resin 14 formulas aredifferent colors their location within the thickness can be observed. Inmost cases, the resin's 14 interface at the roving/outer mat interfaceis easily seen. Sample preparation techniques are described inPreparation and Examination of Aluminum Samples for Failure Analysis.By. Brad Peirson. School of Engineering. Grand Valley State University.Laboratory Modules 1 & 2. EGR 250 Materials Science, incorporated byreference herein.

FIG. 13 shows a perspective view of the prewet 24 station, with the slot50 being the fixed version. Critical issues regarding the use of theprewet 24 station are the following.

-   -   1. The slot 50 is fixed between the uncompressed thickness of        reinforcement and thickness required for maximum transfer to the        section 52.    -   2. The transfer is controlled by input mass flow and ability of        keeper D to prevent flow out the rear of the die.    -   3. As long as the input mass flow and output on the        reinforcement through slot A is balanced, a constant amount of        resin 14 will be transferred to the donor reinforcement.    -   4. Slot A may be a constant thickness or changed in thickness to        match the needs of the receptor layers for resin 14 along the        width of the part 40. Letter A, as shown in FIG. 16, is one half        the height of the slot. In all cases the keeper D is less than        the either Q or R, whichever is smaller. This forces the flow        forward.    -   5. The resin 14 transfer is varied with speed by adjusting mass        flow input from pump or pressure in the tank.

FIG. 15 shows a top view of the bottom half internally of the prewet 24station.

FIG. 14 is a bottom view of the top half internally of the prewet 24station.

FIG. 16 is a side view of a cross-section of the bottom half of theprewet 24 station,

-   -   A equals one half the height of the slot    -   B equals one half the depth of the reservoir    -   C equals one half the height of the prewet 24    -   D equals half the height of Q or R, whichever is smaller, and to        minimize backflow    -   E is the entrance to the taper    -   F is the resin entrance.

Explanation of the drawing of the three types of slots 50, as shown inFIGS. 17-19.

If you look at the type of “U” channel Werner makes, they can be brokendown into three categories: heavy weight extension and step rail 16,light weight extension rail 16 and light weight step rail 16. Thecharacteristics of each type of rail 16 is that they are all standardseven layer laminates with the same thickness of veil and mat. What ischanged is the amount and distribution of roving throughout the width ofthe part 40.

In the heavy duty step and extension rails 16, the amount per inch ofroving in the flange areas of the U channel are much greater than therelative amount per inch in the web 18. [Section 57821 would be typicalof this type of rail 16. The flange thickness is 0.222 inches of which0.154 in of the thickness is two 0.077 in roving layers. The web 18 ofthis section is 0.165 inch thick. It contains two roving layers of0.0485 in thickness.] Thus, the center donor mat must transfer almosttwice the volume per in of resin 14 into the flange areas of theacceptor layers as it transfers into the web 18 area of the acceptorlayers in order to fully saturate both areas equivalently withoutputting excess resin 14 in the web 18 area which could cause airentrapment in the injection die.

The drawing of the slot 50 with much thicker outside segments representsthe method by which this distribution of resin 14 within the donor matis achieved. The mat would be fully saturated in the prewet 24 in itsuncompressed thickness. The mat would then be differentially stripped bythe slot 50 and allowed to return to its uncompacted state as it exitsthe prewet 24 die. Air would replace the resin 14 that was removed bythe stripping action of the slot 50 as the mat returns to its naturalthickness. By stripping more from the web 18 than the flange sections ofthe donor mat the proper distribution of resin 14 is developed such thatthere is sufficient resin 14 available in the proper location to fullyimpregnate the acceptor roving layers even though the layers are notuniform across the width of the part 40.

The slot 50 with slightly larger outside segments acts the same way asthe previous slot 50 and used for light weight extension rails 16 suchas 62418 where the flange roving layers are about 30% greater inthickness than the web 18 layers.

The uniform slot 50 is used for lightweight step rail 16 where the web18 and the flange are essentially equal in thickness and roving layersare almost uniform across the part 40 width. Part 63101 is an example ofthis.

In all cases the slot 50 design is such that as the donor mat exits theprewet 24 it contains the proper amount of resin 14 that when thereinforcement pack is compress by the injection die to within mils ofits final thickness in the curing die sufficient resin 14 will betransferred from the donor mat to the acceptor rovings so that theacceptor rovings are fully saturated with prewet 24 resin 14.

All the design calculations for slot 50 thicknesses and distributionalong the width are done by looking at the designs of the sections 52and understanding the thicknesses to which various materials willcompress under the pressures induced in the curing die during thepultrusion process. A. McCarty and J. G. Vaughan, A Pressure Rise Insidea Cylindrical Pultrusion Die for Graphite/Epoxy Composites, @ Poly-mersand Polymer Composites, 8 (4) 231-244, 2000. Brief, incorporated byreference herein, discusses the pressure distribution within the curingdie. Microscopic analysis of layer thicknesses has also helped establishthese numbers. The calculation now becomes a simple mass balanceassuming that no air is allowed into the final product (void volumes inpultrusions are normally less than 1% for injection die parts). Volumesof resins 14 are converted into thickness of donor mat and slots 50 aredesigned accordingly. The key to making it all work is to notoversaturate the donor or overcompress the donor acceptor package priorto the curing die.

Referring to FIG. 9, unimpregnated middle mat (I) is pulled at constantspeed through prewet 24 station (X). Prewet 24 station (X) is suppliedwith a controlled mas flow of prewet 24 resin 14 (II) which is balancedto the resin 14 requirements of the section 52 and set by the operatorusing calibrated flow guidelines described previously. The impregnateddonor layer (middle mat) (XI) exits the pulling station X and iscombined (stacked) with top and bottom roving layers (III) and top andbottom mat layers (IV) using the first of two horizontal and verticalpositioners (V). The combined section (XII) proceeds to secondhorizontal vertical position V at which the outside veils (VI) are addedto the top and bottom of the pack. The pack continues to positive veilplacement device (VII) which folds the lower veil around the outer edgesof the pack and over the edges of the top veil. (For colored veil, thisprevents any non-colored reinforcement from being visible on the surfaceof the part 40 and causes the overlap of the top and bottom color veilsto occur at a constant position and with a constant amount of overlappedarea.)

The positive placement device is congruent to the entrance of the partformer (VIII). As the pack continues through the part former (VIII), thepack is folded from a flat section 52 to a “u” channel shape. Duringthat change in geometry, the pack is compressed slightly but notstretched (mats would tear).

From the exit of the folder, the “u” shape pack enters the “tapered”impregnation chamber IX. Where the top coat resin 14 is added andremaining air removed as described by Gauchel and Lehman. (The key tothis on any other process that uses injection is the placement of theresins 14 such that air is forcibly removed from reinforcement pack.Continuous path(s) for air removable must be maintained or blisters willbe evident on the final part 40. Both continuous strand mat and unwetroving act as paths for air from the impregnation weir 42 in theimpregnation (IX) to the space between the entrance of the impregnator26 and the exit of the folder. For a properly running impregnationsystem, the outer layers of the reinforcing package at this positionshould remain free of resin 14, so air can be removed. For thin partssuch as window lineals ran at high speed, the air sounds like a train asit rushes out of the back of the impregnating die. Parts 40 may be asthin as 0.040 inches in wall thickness on a closed hollow section 52.

FIG. 9 shows a schematic of the controller impregnation. Theunimpregnated donor layer enters the prewet 24 station where prewet 24resin 14 is introduced. The now impregnated donor layer passes out ofthe prewet 24 resin 14 station where it is joined with theun-impregnated top mat layer, a top roving layer, the bottom rovinglayer and the bottom mat layer. Horizontal and vertical layer placementguides 48 guide the different layers together to the impregnated donorlayer, As they are pulled along, the top veil and bottom veil layers areadded to them which are again guided by horizontal and vertical layerplacement guides 48. A top veil and bottom veil has tensioning guides 48to maintain the tension on the top and bottom veil layers. All thelayers then pass through a positive veil placement device and then enterthe former 46. The cross-section of the slot 50 through which the layersenter the former 46 is essentially rectangular while the cross-sectionof the slot 50 from which the layers exit the former 46 has a C shape.The former 46 converts the flat with or cross-section of the layers to aC channel cross-section and partially compacts the layers to initiate atransfer of resin 14 from the donor layer to the acceptor layers. Fromthe former 46, the layers move to the impregnator 26. The impregnator 26has a tapered cross-section. High-pressure resin 14 is impregnated intothe layers at the weir 42 located just next to the point of maximumcompaction. The resin 14 is injected into the weir 42 for wetting theouter layers, as described above.

FIG. 10 shows section C of FIG. 9. FIG. 11 shows section B of FIG. 9,and FIG. 12 shows section A of FIG. 9. FIG. 12 shows the five layersthat have been brought together at that point of the process. Thesaturated middle mat 38 with resin is the donor layer and the provinglayers 34, 36 on each side of the middle mat 38 are acceptor layers.

Prewet 24 Station Variable Slot Version

Referring to FIGS. 20 and 21, slot A is adjustable to differentthickness to apply exactly the amount of resin 14 needed. Must beadjusted for each speed or adjusted to maximum speed and allowed totransfer extra resin 14 or start up as speed increases.

Compaction bolts adjust slot A and keeper D as in previous drawing suchthat resin 14 moves forward out of slot A with reinforcement. Inletpressure keeps reservoir full on an as needed basis. Pressure or flowrate can be sporadic as long as reservoir has sufficient resin 14 tosaturate reinforcement (mat) a sit exits slot A.

Referring to FIGS. 22 and 23, there is shown a front view and a backview, respectively, of a continuous former 46. The former 46 convertsthe flat shaped reinforcing pack to the approximate shape of the formedpart 40. The former 46 compacts the reinforcing pack slightly to preventtransfer of prewet 24 resin 14 from the donor layer to acceptor layers.Approximately 30% of transition is accomplished in the former 46. Ifthere is too much compaction, it results in an increased pull the forcedby as much as 50%.

The graphic is printed on fabric using a digital printer, similar towhat is used with a PC, only larger. The graphic is designed or loadedinto a computer and then sent to the digital printer. For instance, theFabric Superior Textile Printer sold by ITNH, Inc., can be used for thispurpose. Graphics on veil can be incorporated with the use of digitalprinting equipment for producing logos, patterns, artwork replications,photographic images, and blends of transitional colors. Through theselection of inks and veil pre-treatments, good graphic resolution andUV resistance can be obtained. Images rendered to digital format canutilize digital printers, dryers, and sublimators to reproduce thoseimages on a veil that comprises the outer wrap of a pultruded composite,such as a ladder side rail. As the veil in its final pultruded form ispositioned below a layer of clear resin, graphics are largely protectedand can not be easily scratched off, as can occur with surface painting.Multiple graphics can be printed in a column arrangement on a singleveil master roll and subsequently slit into narrow rolls to separate theindividual graphics prior to pultrusion, making custom and low volumeproducts economical.

FIGS. 26 and 27 are photographs of portions of ladder rails withgraphics.

Although the invention has been described in detail in the foregoingembodiments for the purpose of illustration, it is to be understood thatsuch detail is solely for that purpose and that variations can be madetherein by those skilled in the art without departing from the spiritand scope of the invention except as it may be described by thefollowing claims.

1. An apparatus for climbing comprising: rails decorated using veilproducts having graphics and having an overcoat Delta E less than orequal to 20 1,000 hours QUV, where 1000 hours QUV equals one year SouthFlorida.
 2. An apparatus as described in claim 1 wherein the graphicsinclude company names, logos, patterns, artwork replications,photographic images, and blends of transitional colors in the veil. 3.An apparatus as described in claim 2 wherein the rails have a glossgreater than
 70. 4. A method for making a ladder rail comprising thesteps of: forming a pultruded section having a graphic on veil; andcutting the section to form the ladder rail.
 5. The combination of aresin having filler levels below 20 pph and coated veil system to createa synergistic weather resistant ladder rail surface with graphics.
 6. Asystem as described in claim 5 including resins made of polyester,acrylic, epoxy, urethane, acrylate, or combinations thereof that utilizethe selection of dyes or inks that possess the combination ofnon-oleophilic and colorfastness properties applied to treated veil thataccepts the dyes or inks in a manner to attain graphic or imageresolution.
 7. A system as described in claim 6 including veils havingdyed, printed, pigmented, transfer coated or combinations thereof.
 8. Asystem as described in claim 7 wherein veil compositions are glass,polyester, paper, jute or other dispersed fiber systems.
 9. A method forproducing ladder rails comprising the steps of: continuously pultrudingparts with differing graphics in controlled positions around theperimeter of the rails and coated with clear resin; and forming therail.
 10. A system for producing components comprising: means forproducing rail having a graphic and having a delta E less than 20 with a60 degree gloss, as measured by a hunter gloss meter, of greater than 70after 1000 hours of accelerated weathering in a QUV chamber using bulb Awith an ASTM cycle; and means for cutting the rail.
 11. A ladder railcomprising: a web having a graphic; a first flange extending from theweb; and a second flange extending from the web, the web and first andsecond flanges made of fiberglass and resin and together forming therail having a delta E less than 20 with a 60 degree gloss, as measuredby a hunter gloss meter, of greater than 70 after 1000 hours ofaccelerated weathering in a QUV chamber using bulb A with an ASTM G154cycle 4 with the web and first and second flanges having an outercoating of clear resin.
 12. A method for producing components comprisingthe steps of: producing rail having a delta E less than 20 with a 60degree gloss, as measured by a hunter gloss meter, of greater than 70after 1000 hours of accelerated weathering in a QUV chamber using bulb Awith an ASTM G154 cycle 4 with the web and first and second flangeshaving an outer coating of clear resin; and cutting the rail.
 13. Asystem for producing a ladder rail comprising: a pultrusion system, thepultrusion system comprising: a prewet which wets a middle mat layerwith a resin and filler; and an impregnator which compresses a firstveil outer layer having a graphic, a second veil outer layer, a firstmat layer, a second mat layer, a first roving layer and a second rovinglayer with the middle mat layer, and which wets only the first veilouter layer, the second veil outer layer, the first mat layer and thesecond mat layer with resin having filler levels below 20 pph.
 14. Asystem as described in claim 13 wherein the first veil outer layercontains clear resin and the second veil outer layer all the colorantneeded to color the ladder rail.
 15. A system as described in claim 14wherein the first and second veil outer layers combined with the resinwithout filler form a corrosion and weathering barrier such that saidladder rail maintains a delta E of less than 20 and 60 degree gloss of60 after exposure to 1000 hours of ASTM G154 Cycle 4 irradiation in aQUV accelerated weathering machine.
 16. A ladder rail comprising: afirst veil layer having a graphic; a first mat layer having a firstcolor in contact with the first veil layer; a first roving layer incontact with the first mat layer; a middle mat layer in contact with thefirst roving layer; a second roving layer in contact with the middle matlayer and together the middle mat and first roving layer having a secondcolor; a second mat layer having the first color in contact with thesecond roving layer; and a second veil layer in contact with the secondmat layer.
 17. A rail as described in claim 16 wherein the first matlayer, and the second mat layer having resin having filler levels below20 pph; and the first and second roving layers and the middle mat layerhaving resin with filler.